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Operating manual
Version 1.0.6
Mill Drill
BF 30 Vario
Item No. 3338438
Optional Stand Item No. 3353004
Keep for future reference!
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Page 2 Mill Drill BF 30 Vario Version 1.0.6 27 / 08 / 2010
Table of Contents
Preface
Changes The illustrations of the mill drill might in some details deviate from the illustrations of this operating
manual but this will have no influence on the operation of the mill drill.
Any changes in the construction, equipment and accessories are reserved for reasons of
enhancement. Therefore, no claims may be derived from the instructions and descriptions.
1 Safety
1.1 Safety warnings (warning notes).............................................................................................5
1.1.1 Classification of hazards..............................................................................................5
1.1.2 Other pictograms.......................................... ... ................................................ ... ......... 6
1.2 Proper use ..............................................................................................................................7
1.3 Possible dangers caused by the mill drill................................................................................7
1.4 Qualification of personnel........................................................................................................8
1.4.1 Target group................................................................................................................8
1.5 Safety measures during operation.................................... ... ................................................... 8
1.6 Safety devices.........................................................................................................................9
1.6.1 EMERGENCY-STOP button........................................................................................ 9
1.6.2 Lockable main switch.................................... ... ... ................................................ ... .... 10
1.6.3 Protective cover.........................................................................................................10
1.6.4 Separating protective equipment....................................................... ........................ 11
1.7 Safety check ......................................................................................................................... 11
1.8 Individual protection gear...................................................................................................... 12
1.9 For your own safety during operation.................................................................................... 12
1.10 Disconnecting the mill drill and making it safe ......................................................................13
1.11 Using lifting equipment.......................................................................................................... 13
2 Technical data
2.1 Power Supply........................................................................................................................ 14
2.2 Milling-drilling capacity.......................................................................................................... 14
2.3 Spindle holding fixture........................................................................................................... 14
2.4 Mill drill head.........................................................................................................................14
2.5 Cross table............................................................................................................................14
2.6 Work area.............................................................................................................................. 14
2.7 Speeds..................................................................................................................................14
2.10 Emissions..............................................................................................................................15
2.8 Environmental conditions......................................................................................................15
2.9 Operating material.................................................................................................................15
2.11 Installation plan............................ .........................................................................................16
2.12 Installation plan of optional stand..........................................................................................17
3 Unpacking and connecting
3.1 Extent of supply .................................................................................................................... 18
3.2 Transport...............................................................................................................................18
3.3 Storage ................................................................................................................................. 19
3.4 Installation and assembly...................................................................................................... 20
3.4.1 Site requirements....................................................................................................... 20
3.4.2 Load suspension point...............................................................................................20
3.4.3 Installation..................................................................................................................20
3.5 First use................................................................................................................................21
3.5.1 Power supply........................................................................................... .................. 21
3.5.2 Cleaning and lubricating............................................................................................ 21
3.5.3 Fill in gear lubricant oil...............................................................................................22
3.6 Optional accessories........................................... .................................................................. 22
4 Operation
4.1 Safety....................................................................................................................................23
4.2 Control and indicating elements............................................................................................23
4.2.1 Control panel ............................................................................................................. 24
4.3 Starting the mill drill............................................................................................................... 25
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4.4 Switching off the mill drill.......................................................................................................25
4.5 Inserting a tool.......................................................................................................................25
4.5.1 Installation..................................................................................................................25
4.5.2 Disassembly...............................................................................................................26
4.5.3 Use of collet chucks...................................................................................................26
4.6 Clamping the workpieces......................................................................................................26
4.7 Changing the speed range................................. ... ................................................................27
4.8 Selecting the speed.................................................................................................... ... ........27
4.8.1 Standards values for cutting speeds..........................................................................27
4.8.2 Standard values for speeds with HSS – Eco – twist drilling (U.S. unit.......................29
4.9 Manual spindle feed with the fine feed..................................................................................30
4.10 Manual spindle feed with the spindle quill lever ....................................................................30
4.11 Digital display for spindle travel.............................................................................................30
4.11.1 Technical data............................................................................................................30
4.11.2 Design........................................................................................................................30
4.12 Troubleshooting.....................................................................................................................31
4.13 Swivelling the mill drill head ..................................................................................................31
5 Maintenance
5.1 Safety....................................................................................................................................32
5.1.1 Preparation ................................................................................................................32
5.1.2 Restarting...................................................................................................................33
5.2 Inspection and maintenance .................................................................................................33
5.3 Repair....................................................................................................................................38
6 Spare parts - BF30 Vario
6.1 Column..................................................................................................................................39
6.2 Cross table 1 of 2..................................................................................................................40
6.3 Cross table 2 of 2..................................................................................................................41
6.4 Protection device...................................................................................................................42
6.5 Milling head 1 of 3 .................................................................................................................43
6.6 Milling head 2 of 3 .................................................................................................................44
6.7 Milling head 3 of 3 .................................................................................................................45
6.8 Machine stand (optional).......................................................................................................46
6.9 Parts list.................................................................................................................................47
6.10 Wiring diagram 1 of 2.................................................. .. ................................................ ........52
6.11 Wiring diagram 2 of 2.................................................. .. ................................................ ........53
7 Troubleshooting
7.1 Troubleshooting the mill drill...................................................... ............................................54
8 Appendix
8.1 Copyright...............................................................................................................................55
8.2 Terminology/Glossary ...........................................................................................................55
8.3 LIMITED WARRANTY ..........................................................................................................56
9 Index
Safety
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Page 4 Mill Drill BF 30 Vario Version 1.0.6 27 / 08 / 2010
1 Safety
Glossary of symbols
This part of the operating manual
explains the meaning and use of the warning references contained in the operating
manual,
explains how to use the mill drill properly,
highlights the dangers that might arise for you and others if these instructions are not
obeyed.
In addition to this operating manual please observe
applicable laws and regulations,
legal regulations for accident prevention,
the prohibition, warning and mandatory signs as well as the warning notes on the mill drill.
ALWAYS KEEP THIS DOCUMENTATION CLOSE TO THE MILL DRILL.
INFORMATION
If you are unable to solve a problem using this manual, please contact us for advice:
Exclusive USA Agent
Colovos Company
4444 West Ohio Street
Chicago, IL 60624
Tel.: (773) 533-4216
give additional indications
calls on you to act
enumerations
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Safety
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Page 527 / 08 / 2010 Version 1.0.6 BF 30 Vario Mill Drill
1.1 Safety warnings (warning notes)
1.1.1 Classification of hazards
We classify the safety warnings into various levels. The table below gives an overview of the
classification of symbols (pictograms) and warnings for the specific danger and its (possible)
consequences.
Pictogram
Alarm
Expression
Definition/Consequences
DANGER!
Imminent danger that will cause serious injury or death to
personnel.
WARNING!
Risk: a danger that might cause serious injury or death to
personnel.
CAUTION!
Danger of unsafe procedure that might cause injury to
personnel or damage to property.
ATTENTION!
Situation that could cause damage to the mill drill and
product and other types of damage.
No risk of injury to personnel.
INFORMATION
Application tips and other importan t or useful information
and notes.
No dangerous or harmful consequences for personnel or
objects.
In the case of specific dangers, we replace the pictogram
or
General
danger
with a warning ofinjuries to
hands,
hazardous
electrical
voltage
,
rotating parts.
Safety
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Page 6 Mill Drill BF 30 Vario Version 1.0.6 27 / 08 / 2010
1.1.2 Other pictograms
Warning of
automatic start-up!
Disconnect main power!
Activation forbidden!
Use ear protection!
Use protective
boots!
Use protective gloves!
Wear a safety suit! Protect the environment!
Use protective goggles!
Contact address
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Safety
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1.2 Proper use
WARNING!
In the event of improper use, the mill drill
• will endanger personnel,
• will endanger the mill drill and other material property of the operator,
• may affect proper operation of the mill drill.
The mill drill is designed and manufactured to be used for milling and drilling cold metals or
other non-flammable materials or that do not constitute a health hazard by using commercial
milling and drilling tools.
The mill drill must only be installed and operated in a dry and well-ventilated place.
If the mill drill is used in any way other than described above, or modified without authorization,
then the mill drill- is being used improperly.
We do not take liability for damages caused by improper use.
We would like to stress that any modifications to the construction, or technical or technological
modifications that have not been authorized will also render the warranty null and void.
the maximum values for the mill drill are complied with,
the operating manual is observed,
inspection and maintenance instructions are observed.
„Technical data“ on page 14
WARNING!
Very serious injury due to improper use.
It is forbidden to make any modifications or alterations to the operating values of the mill
drill. These could endanger the staff and cause damage to the mill drill.
1.3 Possible dangers caused by the mill drill
The mill drill was built using the latest technological advances.
Nonetheless there remains a residual risk, since the mill drill operates with
high revolutions,
rotating parts and tools,
electrical voltage and currents.
We have used construction resources and safety techniques to minimise the health risk to the
staff resulting from these hazards.
If the mill drill is used and maintained by personnel who are not duly qualified, there may be a
risk by the mill drill resulting from incorrect operation or unsuitable maintenance.
All personnel involved in assembly, commissioning, operation and maintenance must
be duly qualified,
strictly follow this operating manual .
Disconnect the mill drill from the electrical power whenever cleaning or maintenance work is
being carried out.
Safety
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Page 8 Mill Drill BF 30 Vario Version 1.0.6 27 / 08 / 2010
WARNING!
The mill drill may only be used with the safety devices activated.
Disconnect the mill drill from the electrical power whenever you detect a failure in the
safety devices or when they are not fitted!
All additional installations carried out by the operator need to incorporate the prescribed
safety devices.
As the machine operator, this will be your responsibility!
„Safety measures during operation“ on page 8
1.4 Qualification of personnel
1.4.1 Target group
This manual is addressed to
the operator,
the user,
the maintenance staff.
The warning notes therefore refer to both operation and maintenance of the mill drill.
Always disconnect the mill drill plug from the electrical power. This will prevent it being used by
unauthorised staff.
INFORMATION
All personnel involved in assembly, commissioning, operation and maintenance need to
be duly qualified,
strictly follow this operating manual .
In the event of improper use
there may be a risk to the staff,
there may be a risk to the mill drill and other material property,
may affect proper operation of the mill drill.
1.5 Safety measures during operation
CAUTION!
Risk due to inhaling health hazardous dusts and mist.
Depending on the material being processed and any additional dusts and mist in the
work area, conditions might impair your health.
Make sure that the generated health hazardous dusts and mist are safely removed at the
point of origin and are collected and/ or filtered from the working area. Use an appropriate dust collection/ filter unit.
CAUTION!
Risk of fire and explosion by using flammable materials or cooling lubricants.
Take additional preventive measures in order to safely avoid health hazards before processing flammable materials (e.g. aluminum, magnesium) or before using flammable
additives (e.g. solvents).
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Safety
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1.6 Safety devices
Use the mill drill only with properly functioning safety devices.
Stop the mill drill immediately if there is a failure in the safety device or if it is not functioning for
any reason.
It is your responsibility!
If a safety device has been activated or has failed, the mill drill must only be used when
the cause of the failure has been removed,
it has been verified that there is no resulting danger for the staff or objects.
WARNING!
If you bypass, remove or override a safety device in any other way, you are endangering
yourself and other personnel working with the mill drill. The possible consequences are
• damage as a result of components or parts of components flying off at high speed,
• contact with rotating part s,
• fatal electrocution.
The mill drill includes the following safety devices:
an EMERGENY-STOP button,
a protective cover at the drill-mill head,
a separating protective equipment on the milling spindle.
WARNING!
The separating protective eq uipment wh ic h is ma de a vailab le and delive red tog ether with
the machine is designed to reduce the risk of workpieces or fractions of them from being
expelled, but not to remove them completely.
1.6.1 EMERGENCY-STOP button
The EMERGENCY-STOP button switches
the mill drill off.
„Starting the mill drill“ on page 25
Fig. 1-1: EMERGENCY-STOP button
ATTENTION!
The EMERGENCY-STOP button switches off the mill drill immediately.
Only press the EMERGENCY-STOP button in case of danger! If the emergency stop button is actuated in order to stop the mill drill generally you might damage tools or
workpieces.
After actuating the button, turn it to the right, in order to restart the machine.
EMERGENCY-STOP
Safety
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Page 10 Mill Drill BF 30 Vario Version 1.0.6 27 / 08 / 2010
1.6.2 Lockable main switch
In the position " 0 " the lockable main
switch can be secured against accidental
or non-authorised switching on by means
of a padlock.
When the main switch is switched off, the
current supply is interrupted, except for
areas marked by the pictogram below.
Fig. 1-2: Main switch
WARNING!
Dangerous voltage even if the main switch is switched off. In areas marked by this picto-
gram, there might be voltage, even if the main switch is switched off.
1.6.3 Protective cover
The drill-mill head is fitted with a protective
cover.
WARNING!
Remove the protective cover only after
the power plug of the mill drill has been
pulled out of the receptacle.
Fig. 1-3: Protective cover
Main switch
Protective cover
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Safety
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Page 1127 / 08 / 2010 Version 1.0.6 BF 30 Vario Mill Drill
1.6.4 Separating protective equipment
Adjust the protective guard equipment to
the correct height before you start working.
To do so, detach the clamping screw,
adjust the required height and retighten
the clamping screw.
A switch is integrated in the fixture of the
spindle protection which monitors that the
cover is closed.
INFORMATION
YOU CANNOT START THE MACHINE IF
THE PROTECTIVE GUARD IS NOT
CLOSED.
Fig. 1-4: Separating protective equipment
1.7 Safety check
Check the mill drill regularly.
Check all safety advices
at the beginning of each shift,
once a week (with the machine in operation),
after every maintenance and repair operation.
Locking screw
General check
Equipment Check OK
Protective covers
Fitted, firmly bolted and not damaged
Labels,
markings
Installed and legible
Run test
Equipment Check OK
EMERGENCY-STOP button
When the EMERGENCY-STOP button is activated, the mill drill
should switch off. A restart will not be possible until the EMERGENCY-STOP button has been unlocked and the ON switch has
been activated.
Separating protective
equipment around the
drilling and milling spindle
Only switch on the mill drill if the protective equipment is closed.
Safety
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Page 12 Mill Drill BF 30 Vario Version 1.0.6 27 / 08 / 2010
1.8 Individual protection gear
For certain work individual protection gear is required.
Protect your face and eyes: During all work and specifically work during which your face and
eyes are exposed to hazards, a safety helmet with a face guard should be worn.
Use protective gloves when handling pieces with sharp edges.
Use safety shoes when you position, dismantle or transport heavy components.
Use ear protection if the noise level (emission) in the workplace exceeds 80 dB (A).
Before starting work, make sure that the prescribed individual protection gear is available at the
workplace.
CAUTION!
Dirty or contaminated body protection gear can cause disease. Clean it each time after it
has been used and once a week.
1.9 For your own safety during operation
WARNING!
Before activating the mill drill, double check that this will not endanger other people and
cause damage to equipment.
Avoid any unsafe working practises:
Make sure your work does not endanger anyone.
The instructions in this manual need to be observed during assembly, handling, main-
tenance and repair.
Use protective goggles.
Turn off the mill drill before measuring the workpiece.
Do not work on the mill drill if your concentration is reduced, for example, because you are
taking medication.
Stay on the mill drill until the working spindle has come to a complete halt.
Use prescribed protection gear. Make sure to wear a well-fitting work suit, when
necessary, a hairnet.
Do not use protective gloves during drilling or milling work.
Unplug the shockproof plug from the electrical power before changing the tool.
Use suitable devices for removing drilling and milling chips.
Make sure your work does not endanger anyone.
Clamp the workpiece tightly before activating the mill drill.
In the description of work with and on the mill drill we highlight the dangers specific to that work.
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1.10 Disconnecting the mill drill and making it safe
Unplug the machine from the electrical power before beginning any maintenance or repair work.
1.11 Using lifting equipment
WARNING!
Use of unstable lifting equipment and load-suspension devices that brea k unde r load c an
cause very serious injury or even death.
Check that the lifting equipment and load-suspension devices are of sufficient load
capacity and are in perfect condition.
Observe the rules for preventing accidents issued by OSHA or other inspection authori-
ties.
Hold the loads properly.
Never walk under suspended loads!
Positions of the signs on the mill drill
Fig. 1-5: BF 30 Vario
Technical data
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2 Technical data
The following information gives the dimensions and weight and is the manufacturer’s authorised
machine data.
2.1 Power Supply
Motor 3 HP, 230V, 1Ph, 60Hz
2.2 Milling-drilling capacity
Drilling capacity in steel 24 mm /0.9" max. diam.
Drilling capacity cast iron 28 mm /1.1" max. diam.
Milling capacity of end-mill cutter 30 mm /1.2" max. diam.
Milling capacity of inserted tooth cutter 75 mm /2.9" max. diam.
Swing 440 mm /17.3"
2.3 Spindle holding fixture
Spindle holding fixture R8
Extraction rod (Draw bar) M12
Qill travel 90 mm /3.5"
2.4 Mill drill head
Swivelling + / - 90°
Gearbox stages 3
Z-axis travel 470 mm /18.5"
2.5 Cross table
Table length 750 mm /29.5"
Table width 210 mm /8.3"
Y-axis travel 200 mm/7.9"
X-axis travel 450 mm /17.7"
T-slots 1/2" slots, three
2.6 Work area
Height 2100 mm /82.7"
Depth 1900 mm /74.8"
Width 2500 mm /98.4"
Total Weight 265 Kg. /584 lbs
2.7 Speeds
Gearbox stage low 80 - 1100 RPM
Gearbox stage middle 160 - 1700 RPM
Gearbox stage rapid 320 - 3100 RPM
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Technical data
27 / 08 / 2010 Page 15Technical data Mill Drill BF 30 Vario ; Version 1.0.6
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2.10 Emissions
The noise level (emission) of the mill drill is below 76 dB(A). If the mill drill is installed in an area
where various machines are in operation, the acoustic influence on the operator of the mill drill
may exceed 85 dB(A).
INFORMATION
This numeric value had been measured on a new machine under conventional operating conditions. Depending on the age or wear of the machine, the noise behavior of the machine might
change.
Furthermore, the extent of the noise emission is also depending on manufacturing
influence factors, such as speed, material and clamping conditions.
INFORMATION
The mentioned numerical value is an emission level and not necessarily a safe
working level.
Unless the degree of noise emission and the degree of noise disturbance are depending on one
another it is not possible to use it in order to reliably determine if it is necessary to take further
preventive measures or not.
The following factors influence the actual degree of the noise disturbance of the
operator:
• Characteristics of the working chamber, e.g. size or damping behavior,
• Other noise sources, e.g. the number of machines,
• Other processes proceeding nearby and the period during which the operator is exposed to
the noise.
Consult OSHA, state and local regulations in orde r to determine complianc e, dangers and risks
to the operator.
CAUTION!
The machine operator has to wear an appropriate ear protection depending on the overall
stress caused by noise and on the basic limit values.
We generally recommend using a sound and ear protection.
2.8 Environmental conditions
Temperature 40 - 95 °F (5 - 35 °C)
Humidity 25 - 80%
2.9 Operating material
BF 30 Vario
Gearbox Oil quantity 1-1/4 Qts. (1.2 L)
628 Mobil (Vis. 100/150)
Blank steel parts Mobilux EP 004, acid-free oil, e.g., motor oil
Technical data
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2.11 Installation plan
Fig. 2-1: Installation plan
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Technical data
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2.12 Installation plan of optional stand
Fig. 2-2: Installation plan of optional stand
Unpacking and connecting
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Page 18 Mill Drill BF 30 Vario Version 1.0.6 Stand 27 / 08 / 2010
3 Unpacking and connecting
INFORMATION
The mill drill comes pre-assembled.
3.1 Extent of supply
When the mill drill is delivered, immediately check that the machine has not been damaged
during shipping and that all components are included. Also check that no fastening screws have
come loose.
Compare the parts supplied with the information on the packaging list.
3.2 Transport
WARNING!
Machine parts falling off forklift trucks or other transport vehicles could cause very
serious or even fatal injuries. Follow the instructions and information on the transport
case.
WARNING!
Use of unstable lifting equipment and load-suspension devices that break u nder load ca n
cause very serious injury or even death.
Check that the lifting and load-suspension gear has sufficient load capacity and that it is
in perfect condition. Observe the rules for preventing accidents issued by OSHA or other
inspection authorities.
Hold the loads properly. Never walk under suspended loads!
Center of gravity
Attachment positions (marking the positions for
the attachment position gear)
Prescribed transport position (marking the top
side)
Means of transportation to be used
Weights
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